Material handling basket

ABSTRACT

A material handling basket is provided comprising a base having two opposing pairs of substantially vertical outer walls. First and second sheet-metal dividers respectively extend between a first and second pair of the opposed vertical outer walls, and have a tab at each opposing end extending toward one of the walls of the first and second pairs of walls. Each of the walls of the first pair of walls has openings for accepting one of the tabs for positioning the first dividers relative to the respective wall; and each of the walls of the second pair of walls has openings for accepting one of the tabs for positioning the second dividers relative to the respective wall. Each of the tabs is rigidly joined to the respective opening to retain the first and second dividers between the first and second pairs of outer walls.

FIELD

Embodiments relate generally to material handling baskets and methods ofmanufacturing such baskets.

BACKGROUND

Material handling baskets are often used for holding workpieces (alsoreferred to herein as “parts”) during a manufacturing process. Forexample, a number of parts may be arranged in a two-dimensional array ina basket, each part in a predetermined position, so that a robotic pickand place gripper can automatically pick up the part. Conventionalmaterial handling baskets are typically made of metal wire that iswelded together, with plastic supports called “prongs” attached to themetal wire for vertical support of parts at predetermined locations inthe basket, so a robot gripper can pick up the part.

These conventional wire baskets have several important disadvantages.They have many welds and are made of many parts, especially when theyhave plastic prongs. This requires expensive fixturing for manufacturingthe baskets, and also requires many manufacturing steps, resulting inhigh costs and manufacturing time. Additionally, the welds cause heatdistortion and deformation, so the parts cannot be accurately located inthe basket with the parallelism and perpendicularity required byprecision robots and grippers. In particular, the plastic prongs tendnot to support parts with consistent perpendicularity, and may allowparts to move and change position. This variation in perpendicularityprevents robotic pick and place grippers from picking up parts in theirassigned space, causing the robots to crash. This means themanufacturing machines cannot be run at full speed, and requireexpensive personnel tending the robots to correct problems.

Another disadvantage is that the vertical outside supports or “ledges”typical of wire baskets can interfere with grippers due to their sizeand position. These basket structures encroach into useful space,effectively reducing the capacity of the baskets by acting as obstaclesto the free movement of the robot grippers. In such cases, parts cannotbe loaded onto prongs located next to the vertical supports of thebasket, thereby reducing manufacturing efficiency.

There exists a need for a material handling basket that is simpler andless expensive to manufacture, can be manufactured with the properprecision, and holds parts with the accuracy needed by robotic grippers.There also exists a need for a basket that maximizes useful space forparts, and does not have supports and/or welds that encroach into theinterior of the basket and interfere with grippers.

SUMMARY

One or more embodiments can include a material handling basketcomprising a sheet-metal base having two opposing pairs of substantiallyvertical outer walls, each of the outer walls having a substantiallyhorizontal bottom portion extending from a bottom of the wall towardsits opposite wall, each of the walls joined to an adjacent wall to forma corner with the adjacent wall. A first sheet-metal divider extendsbetween a first pair of the opposed vertical outer walls, and has a tabat each opposing end extending toward one of the walls of the first pairof walls. A second sheet-metal divider extends between a second pair ofthe opposed vertical outer walls, and has a tab at each opposing endextending toward one of the walls of the second pair of walls. Each ofthe walls of the first pair of walls has an opening for accepting one ofthe tabs for positioning the first divider relative to the respectivewall; and each of the walls of the second pair of walls has an openingfor accepting one of the tabs for positioning the second dividerrelative to the respective wall. Each of the tabs is rigidly joined tothe respective opening to retain the first and second dividers betweenthe first and second pairs of outer walls.

Embodiments further include a basket comprising a prong having acruciform cross-section, the prong extending upwardly from a bottom ofthe basket. The prong has a plurality of outer surfaces for engaging oneor more inner surfaces of a workpiece to be supported in the basket bythe prong, the prong outer surfaces cooperating with each other and withthe one or more inner surfaces of the workpiece to hold the workpiece ina predetermined position in the basket, such that the workpiece issubstantially stationary relative to the basket.

Embodiments further comprise method of manufacturing a basket, themethod comprising providing a sheet-metal base having two opposing pairsof substantially vertical outer walls, each of the outer walls having asubstantially horizontal bottom portion extending from a bottom of thewall towards its opposite wall, each of the walls joined to an adjacentwall to form a corner with the adjacent wall. A plurality of firstsheet-metal dividers is also provided for extension between a first pairof the opposed vertical outer walls, each of the first dividers having atab at each opposing end. Additionally, a plurality of secondsheet-metal dividers is provided for extension between a second pair ofthe opposed vertical outer walls, each of the second dividers having atab at each opposing end. The pluralities of first and second dividerseach have slots for engaging each other, and each wall of the first pairof outer walls has openings for accepting the tabs of respective ones ofthe plurality of first dividers, and each wall of the second pair ofouter walls has openings for accepting the tabs of respective ones ofthe plurality of second dividers.

The method further comprises engaging the slots of the pluralities offirst and second dividers with each other to form a grid having aplurality of intersections; engaging each tab of the pluralities offirst and second dividers with a corresponding opening in one of thewalls of the first and second pairs of outer walls to position the firstdividers and second dividers relative to the first and second pairs ofouter walls; and rigidly joining each of the tabs to the correspondingopening to retain the first and second dividers between the first andsecond pairs of outer walls.

Objects and advantages of embodiments of the disclosed subject matterwill become apparent from the following description when considered inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will hereinafter be described in detail below with referenceto the accompanying drawings, wherein like reference numerals representlike elements. The accompanying drawings have not necessarily been drawnto scale. Where applicable, some features may not be illustrated toassist in the description of underlying features.

FIG. 1A is a top perspective view of a material handling basketaccording to an embodiment of the present disclosure.

FIG. 1B is a top perspective view of a base of the basket of FIG. 1A.

FIGS. 1C and 1D are perspective views of dividers of the basket of FIG.1A.

FIG. 1E is a top perspective view of a divider grid of the basket ofFIG. 1A.

FIG. 1F is partial perspective view of the basket of FIG. 1A.

FIG. 1G is a front view of a prong of the basket of FIG. 1A.

FIG. 1H is a cross-sectional view of the prong of FIG. 1G supporting aworkpiece.

FIG. 1I is a front perspective view of a lid for the basket of FIG. 1Aaccording to an embodiment of the present disclosure.

FIG. 1J is a front view of a stack of three of the baskets of FIG. 1Aand the lid of FIG. 1I.

FIG. 2A is a top perspective view of a material handling basketaccording to a further embodiment of the present disclosure.

FIG. 2B is a bottom perspective view of the basket of FIG. 2A.

FIG. 2C is a top perspective view of a divider grid of the basket ofFIG. 2A.

FIG. 2D is top view of the basket of FIG. 2A.

FIG. 2E is top view of the basket of FIG. 2A holding workpieces.

FIG. 2F is cross-sectional front view of the basket of FIG. 2A holdingworkpieces.

FIG. 2G is a top perspective view of a stack of two of the basketsaccording to FIG. 2A.

FIG. 3A is top perspective view of a material handling basket accordingto another embodiment of the present disclosure.

FIG. 3B is a top view of the basket of FIG. 3A.

FIGS. 4A and 4B are top and bottom perspective views, respectively, of amaterial handling basket according to another embodiment of the presentdisclosure.

FIG. 5 is a flow chart of an exemplary method of manufacturing amaterial handling basket according to an embodiment of the presentdisclosure.

DETAILED DESCRIPTION

It should be understood that the principles described herein are notlimited in application to the details of construction or the arrangementof components set forth in the following description or illustrated inthe following drawings. The principles can be embodied in otherembodiments and can be practiced or carried out in various ways. Also,it is to be understood that the phraseology and terminology used hereinis for the purpose of description and should not be regarded aslimiting.

Disclosed herein are material handling baskets for supporting aplurality of workpieces in an array, and methods for manufacturing suchbaskets. The disclosed baskets comprise a sheet metal base and dividerswhich snap together, thereby eliminating the need for fixturing duringassembly. The base and dividers can be laser cut for improvedtolerances, and welded and/or riveted together only on the exterior—notthe interior or bottom—to reduce heat distortion and improveparallelism. In certain embodiments, the workpieces are supported in thedisclosed basket on cruciform prongs formed by the dividers. The prongsare contoured to fit the workpieces so that they grip the workpieces,enabling the workpieces to rest on the prongs accurately and securelywithout falling off or moving, as disadvantageously occurs withconventional baskets. The “low profile” of the disclosed baskets' sheetmetal construction, the precision of their construction, and the abilityof their prongs to securely hold workpieces in the proper position,enable the disclosed baskets to increase manufacturing throughput whenused in conjunction with robotic pick and place grippers and other suchmachines.

FIGS. 1A-1J illustrate an exemplary embodiment of a material handlingbasket according to the present disclosure. In this embodiment, aplurality of workpieces are held in predetermined positions in thebasket by an array of prongs. Referring now to FIGS. 1A-E, a basket 100comprises a sheet-metal base 101, such as a steel or aluminum base,having two opposing pairs of substantially vertical outer walls 102 a,102 b, each of the outer walls 102 a, b having a substantiallyhorizontal bottom portion 103 a, 103 b extending from a bottom of thewall 102 a,b towards its opposite wall 102 a,b. Outer walls 102 a,b areshown having different lengths such that the basket 100 has an overallrectangular shape. However, those of skill in the art will understandthat outer walls 102 a,b can have the same length if desired. In certainembodiments, base 101 is laser cut and deburred, and formed from asingle flat sheet of metal, which is bent into the desired shape. Lasercutting for the base 101 as well as other parts of basket 100 isadvantageous insofar as the basket 100 can be made to tighter tolerancesthan conventional wire baskets. Consequently, workpieces are held bybasket 100 more consistently in the proper place.

Each of the walls 102 a,b is joined to an adjacent wall 102 a,b to forma corner 104 with the adjacent wall 102 a,b. Each corner 105 has acorner tab 105 extending from one of the vertical outer walls (FIG. 1Bshows corner tabs 105 extending from walls 102 b) and contacting anadjacent outer wall 102 a. A weld joint or a rivet 106 rigidly attachesthe corner tab 105 to the adjacent outer wall 102 a. The welds 106 canbe; for example, conventional TIG or MIG welds or resistance spot weldsthat are close to being flush with the surface of the walls 102 a, sothey do not interfere with placement of the basket 100 in a machine. Inthe alternative, conventional rivets can be advantageously used toreduce distortions to the metal from welding heat, and to provideadditional strength to the joints.

Each of the vertical outer walls 102 a,b comprises a plurality of windowopenings 107. In certain embodiments, some of the plurality of openingsin at least one pair of the outer walls 102 a,b comprise finger holes108 for allowing a user to insert a finger or fingers to lift the basket100. In these embodiments, basket 100 does not need added handles thatprotrude and could obstruct robotic grippers that are typically used inconjunction with baskets 100 in a manufacturing context.

Referring particularly to FIGS. 1C-E, basket 100 further comprises agrid 109 of substantially perpendicular first sheet metal dividers 110and second sheet metal dividers 111, all of which are laser cut anddeburred prior to assembly. The first sheet-metal dividers 110 extendbetween a first pair of the opposed vertical outer walls 102 a, and thesecond sheet-metal dividers 111 extend between a second pair of theopposed vertical outer walls 102 b. A plurality of the first dividers110 has a tab 112 at each opposing end extending toward one of the walls102 a of the first pair of walls, and each of the walls 102 a of thefirst pair of walls has openings 113 each for accepting one of the tabs112 for positioning the first dividers 110 relative to the respectivewalls 102 a. Likewise, a plurality of the second dividers 111 each havea tab 114 at each opposing end extending toward one of the walls 102 bof the second pair of walls, and each of the walls 102 b of the secondpair of walls has an opening 115 for accepting one of the tabs 114 forpositioning the second dividers 111 relative to the respective walls 102b.

Additionally, each divider 110, 111 of the pluralities of first andsecond dividers has slots 116, 117 for engaging each other such that thefirst and second dividers 110, 111 can be positioned relative to eachother to form the grid 109 having a plurality of intersections 118.

Each of the first divider tabs 112 is rigidly joined, as by a weld joint119, to a respective opening 113 in one of the walls 102 a to retain thefirst dividers 110 between the outer walls 102 a. Likewise, each of thesecond divider tabs 114 is rigidly joined, as by a weld joint 120, to arespective opening 115 in one of the walls 102 b to retain the seconddividers 111 between the outer walls 102 b. Because the disclosed basket100 includes only a small number of welds, on exterior surfaces only andnot on bottom or interior surfaces, heat distortion during themanufacturing process is reduced, and parallelism is improved versusconventional wire baskets.

In the present embodiment, each of the intersections 118 of the grid 109comprises a first extended portion 121 of one of the first dividers 110and a second extended portion 122 of one of the second dividers 111, thefirst and second extended portions 121, 122 together forming a prong 125having a cruciform cross-section, as shown close-up in FIG. 1F. Prong125 extends upwardly from a bottom of the basket 100. Basket 100 canhold an array of workpieces on respective prongs 125. Referring now toFIGS. 1G-H, prong 125 has a plurality of outer surfaces 126 for engagingone or more inner surfaces 127 a of workpiece 127 to be supported in thebasket 100 by the prong 125, the prong outer surfaces 126 cooperatingwith each other and with the one or more inner surfaces 127 a of theworkpiece 127 to hold the workpiece 127 in a predetermined position inthe basket 100 such that the workpiece 127 is substantially stationaryrelative to the basket 100.

In certain embodiments, the top portions 126 a prong outer surfaces 126are contoured to fit the workpiece 127, advantageously resulting inreduced abrasion between the prong 125 and the workpiece 127, therebyavoiding marring and scratching of workpiece 127. Additionally, sincethe prongs 125 fit the workpieces 127, the workpieces 127 restaccurately and securely in the basket 100 without falling off the prongs125. This advantageously eliminates the need for prongs having plastictines, as in conventional material handling baskets, which are costly tomake and install, and do not accurately align workpieces within thebasket. Accurate placement and retention of workpieces 127 in basket 100is crucial when basket 100 is to be used in conjunction with roboticgrippers that pick up the workpieces 127.

The disclosed basket 100 comprises mostly flat metal outer and innerwalls and surfaces, eliminating the wire supports and ledges ofconventional baskets, which encroach into useful space and interferewith robotic grippers. The design of basket 100 enables robotic grippersto pick parts that are supported practically anywhere in the basket 100(i.e., at all the intersections 118 of the grid 109), thereby improvingutilization.

Each of the vertical outer walls 102 a,b of the base 101 also comprisesa vertically-extending stacking tab 130 at a top of the wall 102 a,b,and a stacking slot 131 at a bottom of the wall 102 a,b. As shown inFIG. 1A, stacking tab 130 and slot 131 are each for engaging acorresponding stacking slot 130 or stacking tab 131, respectively, of asecond basket 100, for stacking the basket 100 and the second basket100. Those of skill in the art will understand that additional baskets100 can also be stacked, as depicted in FIG. 1J showing three stackedbaskets 100. Since the stacking tabs and slots are integrated with thebasket, they are sturdy and eliminate the need for welds and ledges ofconventional wire baskets, which encroach into useful space andinterfere with robot grippers.

Referring now to FIGS. 1I-J, the disclosed basket 100 of this embodimentcan further comprise a removable lid 140 attachable to a top of each ofthe vertical outer walls 102 a,b. Lid 140 comprises a sheet-metal lidbase 141 having first and second opposing pairs of substantiallyvertical outer lid walls 142 a, 142 b corresponding to the two opposingpairs of outer walls 102 a, 102 b of the basket base 101, each of thelid walls 142 a,b joined to an adjacent lid wall 142 a,b to form acorner 143 with the adjacent lid wall 142 a,b. Lid 140 also has a lidbottom 144 extending between the outer lid walls 142 a,b. Lid bottom 144is for constraining movement of each of the workpieces 127 supported byeach of the prongs 125 when the lid 140 is attached to the top of theouter walls 102 a,b of basket 100. This can be accomplished by the lidbottom 144 engaging the grid 109 of basket 100 or the workpieces 127. Inthe illustrated example, openings 145 are provided in the lid bottom 144and engage workpieces 127. Thus, lid 140 will constrain workpieces 127if they are flipped over; for example, in a parts washer.

In certain embodiments, the lid 140 comprises first and secondsheet-metal lid dividers 146, 147 respectively extending between thefirst and second pairs of the opposed vertical outer lid walls 142 a,b.Each of the first and second lid dividers 146, 147 has a tab 148, 149 ateach opposing end extending toward one of the lid walls 142 a,b of thefirst and second pairs of outer lid walls, and each of the lid walls 142a, 142 b has an opening 150, 151 for accepting one of the tabs 148, 149for positioning the first and second dividers 146, 147 relative to therespective lid walls 142 a,b. Each of the tabs 148, 149 is rigidlyjoined, as by welding, to the respective opening 150, 151 in one of thelid walls 142 a,b to retain the first and second dividers 146, 147between the first and second pairs of outer walls 142 a,b. At least oneof the first and second lid dividers 146, 147 has a slot (not shown) forengaging the other one of the first and second lid dividers 146, 147when the first and second lid dividers 146, 147 are positioned relativeto the first and second pairs of outer lid walls 142 a,b.

As discussed herein above and shown in FIG. 1A, each of the verticalouter walls 102 a,b of the basket 100 comprises a vertically-extendingstacking tab 130 at the top of the wall. The lid base 141 has acorresponding lid slot 146 at a bottom of each of the vertical outer lidwalls 142 a,b for engaging a corresponding basket stacking tab 130, forattaching the lid 140 to the basket 100. FIG. 1J shows lid 140 attachedto a basket 100.

As also discussed in detail herein above, a number of baskets 100 can bestacked. As shown in FIG. 1J, the outer lid walls 142 a,b have a heighth such that when the lid 140 is attached to a basket 100, and the basket100 and one or more additional baskets 100 are stacked, a total height Hof the stacked baskets 100 and the lid 140 is substantially equal to apredetermined total height. Thus, the lid height h can be selected toadjust the total height H so the stack fits inside a cavity, such as acavity of a parts washer.

An alternative embodiment of the disclosed basket will now be describedwith reference to FIGS. 2A-2G. In this embodiment, the dividers do nothave extended portions that form cruciform prongs to hold workpieces.Rather, the dividers form compartments to hold workpieces, along with abottom portion of the basket base. Otherwise, the basket of thisembodiment is similar or identical in most major respects to the basket100 of the embodiment of FIGS. 1A-E described herein above.

As shown in FIGS. 2A-D, a basket 200 comprises a sheet-metal base 201,such as a steel or aluminum base, having two opposing pairs ofsubstantially vertical outer walls 202 a, 202 b, each of the outer walls202 a,b having a substantially horizontal bottom portion 203 a, 203 bextending from a bottom of the wall 202 a,b towards its opposite wall202 a,b. Base 201 also has a bottom member 203 c extending between thehorizontal bottom portions 203 a,b. Bottom member 203 c can be formedintegrally with the base 201 as shown in FIGS. 2B. Outer walls 202 a,bare shown having different lengths such that the basket 200 has anoverall rectangular shape. However, those of skill in the art willunderstand that outer walls 202 a,b can have the same length if desired.In certain embodiments, base 201 is laser cut and deburred, and formedfrom a single flat sheet of metal, which is bent into the desired shape.Laser cutting for all the base 201 as well as other parts of basket 200is advantageous insofar as the basket 200 can be made to tightertolerances than conventional wire baskets. Consequently, workpieces areheld by basket 200 more consistently in the proper place.

Each of the walls 202 a,b is joined to an adjacent wall 202 a,b to forma corner 204 with the adjacent wall 202 a,b. Each corner 205 has acorner tab 205 extending from one of the vertical outer walls andcontacting an adjacent outer wall (in FIGS. 2A-B corner tabs 205 extendfrom walls 202 a). Rivets 206 or welds, which are close to being flushwith the surface of the walls 202 a, rigidly attach the corner tab 205to the adjacent outer wall 202 a. Conventional rivets 206 can beadvantageously used to reduce distortions to the metal from weldingheat, and to provide additional strength to the joints. Each of thevertical outer walls 202 a,b and the bottom member 203 c comprises aplurality of window openings 207.

Referring in particular to FIG. 2C, basket 200 further comprises a grid209 of substantially perpendicular first sheet metal dividers 210 andsecond sheet metal dividers 211, all of which are laser cut and deburredprior to assembly. The first sheet-metal dividers 210 extend between afirst pair of the opposed vertical outer walls 202 a, and the secondsheet-metal dividers 211 extend between a second pair of the opposedvertical outer walls 202 b. A plurality of the first dividers 210 has atab 212 at each opposing end extending toward one of the walls 202 a ofthe first pair of walls, and each of the walls 202 a of the first pairof walls has openings 213, each for accepting one of the tabs 212 forpositioning the first dividers 210 relative to the respective walls 202a. Likewise, a plurality of the second dividers 211 each have a tab 214at each opposing end extending toward one of the walls 202 b of thesecond pair of walls, and each of the walls 202 b of the second pair ofwalls has an opening 215 for accepting one of the tabs 214 forpositioning the second dividers 211 relative to the respective walls 202b.

Each divider 210, 211 of the pluralities of first and second dividersalso has slots 216, 217 for engaging each other (similar to slots 116and 117 respectively shown in FIGS. 1C and 1D) such that the first andsecond dividers 210, 211 can be positioned relative to each other toform the grid 209 having a plurality of intersections 218. Additionally,each divider 210 has a number of bottom tabs 221 extending towards thebottom member 203 c, each divider 211 has a number of bottom tabs 222extending towards the bottom member 203 c, and the bottom member 203 chas corresponding slots 223, 224 for engaging respective bottom tabs221, 222.

Each of the first divider tabs 212 is rigidly joined, as by a weldjoint, to a respective opening 213 in one of the walls 202 a to retainthe first dividers 210 between the outer walls 202 a. Each of the seconddivider tabs 214 is rigidly joined, as by a weld joint, to a respectiveopening 215 in one of the walls 202 b to retain the second dividers 211between the outer walls 202 b. Likewise, each of the bottom tabs 221,222 is rigidly joined, as by a weld joint, to a respective slot 223, 224in bottom member 203 c to retain the first and second dividers 210, 211to the bottom member 203 c. Because the disclosed basket 200 includesonly a small number of welds, on the exterior walls only and not onbottom or interior surfaces, heat distortion during the manufacturingprocess is reduced, and parallelism is improved versus conventional wirebaskets.

As shown in FIGS. 2D-F, basket 200 can hold an array of workpieces 227in respective compartments 226 formed by the grid 209 along with bottommember 203 c and outer walls 202 a,b. The surfaces of the grid 209, thebottom member 203 c, and (in some compartments 226) the outer walls 202a,b cooperate with each other to hold one workpiece 227 in apredetermined position in the basket 200.

Each outer wall 202 a of the base 201 comprises one or more hoist arms208 for engaging an overhead lifting device (not shown) for lifting thebasket 200. Each outer wall 202 a also includes one or more stackingslots 228 at a bottom of the wall 202 a. Each hoist arm 208 acts as avertically-extending stacking tab, for engaging a corresponding stackingslot 228 of a second basket 200, for stacking the basket 200 and thesecond basket 200, as depicted in FIG. 2G. Those of skill in the artwill understand that additional baskets 200 can also be stacked.

In certain similar embodiments shown in FIGS. 3A-B, a basket 300 similarin most relevant respects to basket 200 has a bottom member 301 withopenings 302, and further comprises a mesh member 303 attached to thebottom member 301 and extending over openings 302. Basket 300 alsodiffers from basket 200 in that it has a pair of handles 304 rather thanhoist arms, and the handles 304 facilitate stacking of multiple baskets300.

In further similar embodiments shown in FIGS. 4A-B, a basket 400 similarin most relevant respects to basket 200 has a bottom member 401 withopenings 402, and further comprises a mesh member 403 attached to thebottom member 401 and extending over openings 402. Basket 400 also has asheet-metal lid 404 attachable to a top of each of the basket's verticalouter walls 405 by at least one or more hinges 406 and latches 407. Thelid 404 is for engaging the grid 408 of dividers for constrainingmovement of workpieces (not shown) held by the grid 408.

A method will now be described for manufacturing the disclosed basket,with reference to FIGS. 1A-1E and the flow chart of FIG. 5. At step 501,a sheet-metal base 101 is provided having two opposing pairs ofsubstantially vertical outer walls 102 a, 102 b, each of the outer wallshaving a substantially horizontal bottom portion 103 a, 103 b extendingfrom a bottom of the wall towards its opposite wall, each of the walls102 a,b joined to an adjacent wall to form a corner 104 with theadjacent wall. In certain embodiments, base 101 is laser cut, andproviding the sheet-metal base 101 comprises forming the horizontalbottom portion 103 a,b of each of the outer walls 102 a,b integrallywith one of the outer walls 102 a,b.

At step 502, a plurality of first sheet-metal dividers 110 is providedfor extension between a first pair of the opposed vertical outer walls102 a, each of the first dividers 110 having a tab 112 at each opposingend. At step 503, a plurality of second sheet-metal dividers 111 isprovided for extension between a second pair of the opposed verticalouter walls 102 b, each of the second dividers 111 having a tab 114 ateach opposing end. The pluralities of first and second dividers 110, 111each have slots 116, 117, respectively, for engaging each other, andeach wall of the first pair of outer walls 102 a has openings 113 foraccepting the tabs 112 of respective ones of the plurality of firstdividers 110, and each wall of the second pair of outer walls 102 b hasopenings 115 for accepting the tabs 114 of respective ones of theplurality of second dividers 111. In certain embodiments, the dividers110, 111 are laser cut.

At step 504, the slots 116, 117 of the pluralities of first and seconddividers 110, 111 are engaged with each other to form a grid 109 havinga plurality of intersections 118. Then, at step 505, each tab 112, 114of the pluralities of first and second dividers 110, 111 is engaged witha corresponding opening 119, 120 in one of the walls 102 a,b of thefirst and second pairs of outer walls to position the first dividers 110and second dividers 111 relative to the first and second pairs of outerwalls 102 a,b. Finally, at step 506, each of the tabs 112, 114 isrigidly joined to the corresponding opening 113,115 to retain the firstand second dividers 110, 111 between the first and second pairs of outerwalls 102 a,b.

The “snap together” design of the disclosed basket reduces manufacturingtime and cost versus conventional welded-wire baskets. For example, thedisclosed baskets require no fixturing to assemble, and also require amuch smaller number of parts. At the same time, the disclosed snaptogether design results in a stronger basket than conventional weldedwire baskets. It also improves tolerances, facilitating the use ofrobotic pick and place grippers.

While this invention has been described in conjunction with a number ofembodiments, it is evident that many alternatives, modifications andvariations would be or are apparent to those of ordinary skill in theapplicable arts. Accordingly, applicants intend to embrace all suchalternatives, modifications, equivalents and variations that are withinthe spirit and scope of this invention.

What is claimed is:
 1. A basket comprising: a sheet-metal base havingtwo opposing pairs of substantially vertical outer walls, each of theouter walls having a substantially horizontal bottom portion extendingfrom a bottom of the wall towards its opposite wall, each of the wallsjoined to an adjacent wall to form a corner with the adjacent wall; anda first sheet-metal divider extending between a first pair of theopposed vertical outer walls; wherein the first divider has a tab ateach opposing end extending toward one of the walls of the first pair ofwalls, and each of the walls of the first pair of walls has an openingfor accepting one of the tabs for positioning the first divider relativeto the respective wall; and wherein each of the tabs is rigidly joinedto the respective opening to retain the first divider between the firstpair of outer walls.
 2. The basket of claim 1, comprising a secondsheet-metal divider extending between a second pair of the opposedvertical outer walls; wherein the second divider has a tab at eachopposing end extending toward one of the walls of the second pair ofwalls, and each of the walls of the second pair of walls has an openingfor accepting one of the tabs for positioning the second dividerrelative to the respective wall; wherein each of the tabs is rigidlyjoined to the respective opening to retain the second divider betweenthe second pair of outer walls; and wherein at least one of the firstand second dividers has a slot for engaging the other one of the firstand second dividers when the first and second dividers are positionedrelative to the first and second pairs of outer walls.
 3. The basket ofclaim 2, comprising a plurality of the first dividers and a plurality ofthe second dividers, the pluralities of first and second dividers eachhaving slots for engaging each other such that the pluralities of firstand second dividers can be positioned relative to each other to form agrid having a plurality of intersections; wherein each wall of the firstpair of outer walls has openings for accepting the tabs of respectiveones of the plurality of first dividers, and each wall of the secondpair of outer walls has openings for accepting the tabs of respectiveones of the plurality of second dividers, and each of the first andsecond dividers are respectively retained between the first and secondpairs of outer walls.
 4. The basket of claim 1, wherein each of thecorners of the base comprises: a corner tab extending from one of thevertical outer walls and contacting an adjacent outer wall; and a weldjoint or a rivet for rigidly attaching the corner tab to the adjacentouter wall.
 5. The basket of claim 3, wherein each of the intersectionsof the grid comprises a first extended portion of one of the firstdividers and a second extended portion of one of the second dividers,the first and second extended portions together forming a prong whichextends upwardly from a bottom of the basket; wherein the prong has aplurality of outer surfaces for engaging one or more inner surfaces of aworkpiece to be supported in the basket by the prong, the prong outersurfaces cooperating with each other and with the one or more innersurfaces of the workpiece to hold the workpiece in a predeterminedposition in the basket such that the workpiece is substantiallystationary relative to the basket.
 6. The basket of claim 1, whereineach of the vertical outer walls comprises a plurality of windowopenings.
 7. The basket of claim 6, wherein one or more of the pluralityof openings in each of the outer walls comprises a finger hole forallowing a user to insert a finger to lift the basket.
 8. The basket ofclaim 1, wherein each outer wall of one of the opposing pairs ofvertical outer walls comprises a hoist arm for engaging an overheadlifting device for lifting the basket.
 9. The basket of claim 1, whereineach wall of one of the pairs of vertical outer walls comprises avertically-extending stacking tab at a top of the wall, and a stackingslot at a bottom of the wall, for engaging a corresponding stacking slotor stacking tab, respectively, of a second basket, for stacking thebasket and the second basket.
 10. The basket of claim 3, wherein thebase further comprises a bottom member extending between the horizontalbottom portions; and wherein the first dividers and the second dividerseach have a bottom tab extending towards the bottom member, and thebottom member has slots for engaging the bottom tabs of the first andsecond dividers.
 11. The basket of claim 10, wherein the bottom memberhas openings, the basket further comprising a mesh member attached tothe bottom member and extending over the openings.
 12. The basket ofclaim 3, wherein each of the tabs of each of the first and seconddividers is joined to the respective opening of each of the outer wallsby a weld, to respectively retain the first and second dividers betweenthe first and second pairs of outer walls.
 13. The basket of claim 5,further comprising a lid removably attachable to a top of each of thevertical outer walls, the lid comprising: a sheet-metal lid base havingtwo opposing pairs of substantially vertical outer lid wallscorresponding to the two opposing pairs of outer walls of the basketbase, each of the lid walls joined to an adjacent lid wall to form acorner with the adjacent lid wall; and a lid bottom, extending betweenthe outer lid walls, for constraining movement of each of the workpiecessupported by each of the prongs when the lid is attached to the top ofthe outer walls of the basket.
 14. The basket of claim 13, wherein eachwall of one of the pairs of vertical outer walls of the basket comprisesa vertically-extending stacking tab at the top of the wall, and the lidbase has a lid slot at a bottom of each wall of a corresponding one ofthe pairs of vertical outer lid walls for engaging the correspondingstacking tab, for attaching the lid to the basket.
 15. The basket ofclaim 14, wherein each wall of one of the pairs of vertical outer wallsof the basket further comprises a stacking slot at a bottom of the wall,for engaging a corresponding stacking tab of an additional one of thebaskets, for stacking the basket and the additional basket; wherein theouter lid walls have a height such that when the lid is attached to thebasket, and the basket and one or more of the additional baskets arestacked, a total height of the stacked baskets and the lid issubstantially equal to a predetermined total height.
 16. The basket ofclaim 13, wherein the lid comprises first and second sheet-metal liddividers respectively extending between first and second pairs of theopposed vertical outer lid walls; wherein each of the first and secondlid dividers has a tab at each opposing end extending toward one of thelid walls of the first and second pairs of outer lid walls, and each ofthe lid walls of the first and second pairs of outer lid walls has anopening for accepting one of the tabs for positioning the first andsecond dividers relative to the respective lid walls; wherein each ofthe tabs is rigidly joined to the respective opening in one of the lidwalls to retain the first and second dividers between the first andsecond pairs of outer walls; and wherein at least one of the first andsecond lid dividers has a slot for engaging the other one of the firstand second lid dividers when the first and second lid dividers arepositioned relative to the first and second pairs of outer lid walls.17. The basket of claim 10, further comprising a sheet-metal lidattachable to a top of each of the vertical outer walls by at least oneof a latch and a hinge; wherein the lid is for engaging the grid forconstraining movement of workpieces held by the grid.
 18. A method ofmanufacturing a basket, the method comprising: providing a sheet-metalbase having two opposing pairs of substantially vertical outer walls,each of the outer walls having a substantially horizontal bottom portionextending from a bottom of the wall towards its opposite wall, each ofthe walls joined to an adjacent wall to form a corner with the adjacentwall; providing a plurality of first sheet-metal dividers for extensionbetween a first pair of the opposed vertical outer walls, each of thefirst dividers having a tab at each opposing end; providing a pluralityof second sheet-metal dividers for extension between a second pair ofthe opposed vertical outer walls, each of the second dividers having atab at each opposing end; wherein the pluralities of first and seconddividers each have slots for engaging each other, and each wall of thefirst pair of outer walls has openings for accepting the tabs ofrespective ones of the plurality of first dividers, and each wall of thesecond pair of outer walls has openings for accepting the tabs ofrespective ones of the plurality of second dividers; the method furthercomprising: engaging the slots of the pluralities of first and seconddividers with each other to form a grid having a plurality ofintersections; engaging each tab of the pluralities of first and seconddividers with a corresponding opening in one of the walls of the firstand second pairs of outer walls to position the first dividers andsecond dividers relative to the first and second pairs of outer walls;and rigidly joining each of the tabs to the corresponding opening toretain the first and second dividers between the first and second pairsof outer walls.
 19. The method of claim 10, wherein providing thesheet-metal base comprises forming the horizontal bottom portion of eachof the outer walls integrally with one of the outer walls.
 20. A basketcomprising a prong having a cruciform cross-section, the prong extendingupwardly from a bottom of the basket; wherein the prong has a pluralityof outer surfaces for engaging one or more inner surfaces of a workpieceto be supported in the basket by the prong, the prong outer surfacescooperating with each other and with the one or more inner surfaces ofthe workpiece to hold the workpiece in a predetermined position in thebasket such that the workpiece is substantially stationary relative tothe basket.